1 PET & other Plastic Containers: Industry Overview and Innovative Solutions for Food Packaging ILSI ILSI ILSI ILSI- - -INDIA CONFERENCE ON INDIA CONFERENCE ON INDIA CONFERENCE ON INDIA CONFERENCE ON FOOD SAFETY AND SECURITY FOOD SAFETY AND SECURITY FOOD SAFETY AND SECURITY FOOD SAFETY AND SECURITY New Delhi 27-28 February , 2017 Dr. Vijay G. Habbu Senior VP-Reliance Ind. Ltd. Technical Advisor- PCMA, PACE
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1
PET & other Plastic
Containers:
Industry Overview and Innovative Solutions for
Food Packaging
ILSIILSIILSIILSI----INDIA CONFERENCE ONINDIA CONFERENCE ONINDIA CONFERENCE ONINDIA CONFERENCE ON
FOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITY
New Delhi 27-28 February, 2017
Dr. Vijay G. HabbuSenior VP-Reliance Ind. Ltd.
Technical Advisor- PCMA, PACE
Section 1 : Basics of
Packaging
LAYING THE FOUNDATION ON PACKAGING 2
Packaging is an inevitable part of our lives.e.g. food items, pharmaceuticals, electronic goods, books, clothes, letters.
Packaging is needed to fulfil several objectives:
1. Shelf life, i.e. to maintain the organoleptic properties over a long period
2. Preservation – prevent temperature fluctuations, bacterial ingress, dust, etc.
3. Barrier protection – prevent migration of oxygen, water vapor, UV light, etc.
4. Physical protection - from shock, vibration, compression, etc.
5. Security – prevent pilferage and/or tampering. Also for assuring authenticity.
6. Containment or agglomeration - Liquids, powders and granular materials need containment for efficient handling.
Purpose of Packaging-1
3
7. Portion control - Single-serving packaging has a precise amount of contents to control usage.
8. Information transmission - Packages and labels communicate how to use, transport, recycle, or dispose of the package or product. Some types of information are required by governments.
9. Traceability – As per Codex Alimentarius Commission 2004 (Codex), traceability has 3 objectives: - to improve supply management- to facilitate trace-back for food safety & quality purposes, and - to differentiate and market foods with subtle or undetectable quality attributes.
10. Convenience - Packages can have features which add convenience in distribution, handling, stacking, display, sale, opening, reclosing, use, and reuse.
11. Marketing - The packaging and labels can be used by marketers to encourage potential buyers to purchase the product.
Purpose of Packaging-2
4Packaging essential for preservation, dispensation and information
Packaging materials : the gamut
Global segment breakup of packaging materials (%)
5All packaging materials are SYNTHETIC &/or need external processing
Did you
know?
Producing a plastic bag
consumes only
3%of the
fresh water needed to produce a paper bag
Trends in Packaging – Plastics (1)
Plastics are increasingly replacing traditional materials
7Even glass, metal and paper containers need to have plastics in their closures or COATING of polymers !!!
Evolution is Natural, Inevitable and Irreversible
Trends in Packaging – Plastics (2)
8
• Packaging is one of the fastest growing industries ~ USD 700 billion GLOBALLY.
13Fascinating evolution of synthetic plastics over the past 110 years
PolymerizationPolymer Manufacturers
Polymer/Resin
Injection Moulding
Blow Moulding
Roto Moulding
Colorants AdditivesPlastics/Articles
• Extrusion
• Casting
• Moulding
Convertors
Catalyst
Petrochemical RefinersMonomers• Globally, 20
• 5 in India
• 6 for all plastics (in India)
• 3 for PET (in India)
• 50,000 for all plastics (in India)
• 1500 for PET (in India)
Plastics Formation Process
Very Large Scale
Large Scale
Small Scale
14Converting plastic resins into shaped articles is very simple and gentle
• Originally developed by the Society of the Plastics Industry (now PLASTICS) in 1988, but being administered by ASTM International since 2008
• The RIC system was designed to make it easier to sort and separate plastic items according to their resin type
• In its original form, the symbols consisted of arrows that cycle clockwise to form a triangle that enclosed a number
• In the 2013 revision to the RIC, the ‘chasing arrows’ have been replaced with a solid triangle, in order to address consumer confusion about the meaning of the RIC
However, in India
IS 14534 (1998) : HAS RETAINED THE TRIANGLES WITH CHASING ARROWS
Resin Identification Codes for Plastics
15Codes help the consumer identify the type of plastic
Plastic
Identification
Code
Name of the plastic
(Polymer)
Constituents of the plastic
(Monomers)
Typical End Uses
(Food & Non-Food)
Polyethylene terephthalate
(PET, PETE)
Terephthalic acid + isophthalic acid +
Ethylene glycol (or MEG)
Bottles, Containers, Jars, Films, Strappings, Fibre and
Plastics for Food packaging : governing regulations
36
Till date about 1100 Indian Standards on various plastic products and their test methods have
been developed and about 150 are at various stages of development.
Indian Studies on PET Bottles
CFTRI, Mysore
� Global Migration Studies:
� for compliance with US FDA 21 CFR
§177.1630 (2011) < 0.5 mg/in2 and
� for compliance with BIS: 12252-1987
(2005) (Extractable <10 mg/dm2 and <
60 ppm)
ITRC, Lucknow
� Global Migration
� Heavy Metals
� Biological tests
CU Shah College of Pharmacy, Mumbai
� Stability study on a Cough syrup in Plastic
Containers
These actual studies establish that PET is a safe container
Indian Institute of Packaging, Mumbai
� Global Migration
Italab Pvt. Ltd., Mumbai
� Systemic Injection test
� Intracutaneous test
Intertek, Mumbai (Nov 2014)
� Heavy metals
Shriram Institute for Industrial Research, New Delhi
(Nov 2014)
� Heavy metals37
PET : has been around for a long time, the world over
PET is one of the SAFEST materials38
PET fibres
being made for
more than
65 years
PET bottles
• have been made for more than 42 years
• manufactured all over the world
• more than 300 million MT already used globally
• more than 15 trillion bottles packed and consumed
NO EPIDEMIOLOGICALLY ADVERSE OBSERVATION GLOBALLY
• No case reported on any occupational hazards faced by the work-force (inhalation ingress)
• No case of health effects on civilian consumers (oral ingress)
• No case of health effects due to draping garments (dermal ingress)
• Not a single clinical evidence correlating any ailment with PET chemistry
Section 4 :
Sustainable Plastic
Packaging
PLASTICS ARE MOST ENVIRONMENTALLY BENIGN MATERIALS 39
• Recycling of plastics - is a prime area for innovation and sustainability
• In India, ~3500 organized and ~4000 unorganized plastic recycling units.
• Most plastics (PET, PE, PVC, PP, PS) are recycled via mechanical route
• Recycling of plastics ~3.6 MnTPA, provides employment to ~ 1.6 million people
(0.6 million directly, 1 million indirectly)
Recycling of Plastic Packaging : the India story
Sustainability Best Practices
40Paving our way towards a ‘Cleaner and Greener’ nation
Post-Consumer Waste & Collection
Municipal Solid Waste Segregation
Municipal Solid Waste – Indian cities
60,000 MT/day in 300 class I cities
• Wet compostable waste 38%
• Inert waste 49%
• Paper & Paperboard waste 6%
• Plastics waste 4%
Municipal Solid Waste – Indian cities
60,000 MT/day in 300 class I cities
• Wet compostable waste 38%
• Inert waste 49%
• Paper & Paperboard waste 6%
• Plastics waste 4%
Recycling of Plastic Packaging
41Contrary to uniformed perception, plastics constitute the lowest litter
PET – Sustainable Solutions for Waste Management (1)
Recycled Polyester Fibre (r-PSF)
Recycled Yarn r- PET T-shirtPET bottle scrap
Value chain for PET recycling already exists and country has enough capacity for recycling of PET
42PET gets converted into polyester textiles - a sterling ambassador of the circular economy
43
PET – Sustainable Solutions for Waste Management (2)
Environmental care: Institutionalised by the PET industry > 70% PET is recycled
• Plastics are now emerging as a sustainable and a smarter choice for food packaging
• Using alternatives of plastic packaging can result an increase in packaging weight, energy consumption and global warming
Sustainable Packaging : Advantage Plastics
44Plastics provide best sustainability interventions in the packaging value chain
Cost of Packaging
Energy Consumption
Volume of Waste
Weight of Packaging
Paper & Paperboard
Glass
Metal
Sustainable Packaging: Resource Conservation
45Plastics are most friendly to the environment and to the consumers
AVERAGE VALUES
(of data cited earlier)Weight of container
needed for packing
300mL of liquid
EFFECTIVE VALUES
Of
Packaging Material
Emissions E.F. Emissions E.F.
kgCO2/T Gha/T gFactor
(w.r.t. PET)kgCO2/T (Gha/T)
Glass 990 0.24 162 6x 5940 1.44
Aluminium 10840 2.42 15 0.6x 6504 1.45
PET 2240 0.48 24 1x 2240 0.48
Normalisation taking into account
the weight of packing material needed for packing same amount of contents
Normalised Data – GHG Emissions & Ecological Footprints (E.F.)
[1] Accounting for Greenhouse Gas Emissions of Materials at the Urban Scale- Relating Existing Process Life Cycle Assessment Studies to
Urban Material and Waste Composition, Meidad Kissinger et al., Scientific Research, Low Carbon Economy, 2013, 4, 36-44[2] Accounting for the Ecological Footprint of Materials in Consumer Goods at the Urban Scale,
Meidad Kissinger et al., Sustainability 2013, 5, 1960-1973; doi:10.3390/su5051960
Gha/T = Giga hectares/ ton of
packaging material
46
Reduce
Recycle
ReuseRecover
Let us Learn the “4Rs” in Plastics Usage …
Sustainability also needs to be seen as serving the aims of INCLUSIVE GROWTH
Section 5 :
PET : Innovations
PET/PLASTICS: MOST AMENABLE TO INNOVATIONS FOR THE PACKAGING INDUSTRY48
Use of Plastics
Plastics are materials
made of any of a wide
range of synthetic or
Semi-synthetic organics
that can be molded into
solid objects of diverse
shapes
Plastics
Packaging
Building
&
Construction
Transportation
Electrical
&
Electronics
Medical
&
Health
Agriculture
Sports
&
Leisure
Plastics cover every aspect of your daily life 49
Manifestations of Polymers
1. Plastics
2. Fibres (Textiles)
3. Rubbers / Elastomers
50
4. Coatings
5. Adhesives
6. Cosmetics
Nobel Laureates in Polymer Science
Hermann StaudingerMar 23, 1881-Sep 8, 1965For contributions to the understanding of macromolecular chemistry
Giulio Natta
Feb 26, 1903- May 2 1979
For contributions in polymer synthesis (Ziegler-Natta catalysis).
Paul John Flory
Jun 19, 1910- Sep 9, 1985
For contributions to theoretical polymer chemistry
Pierre-Gilles de Gennes
Oct 24, 1932- May 18, 2007
For describing ordering and phase transitions in polymers.
Alan G. MacDiarmid
Apr 14, 1927- Feb 7, 2007
For work on
conductive polymers
Koichi Tanaka
Aug 3, 1959-
For biological macromolecules
Robert H. Grubbs
Feb 27, 1942-
For olefin metathesis
Karl Waldemar ZieglerNov 26, 1898- Aug 12, 1973
For contributions in polymer
synthesis (Ziegler-Natta catalysis).
Richard R.
SchrockJan 4, 1945-For olefin metathesis
Yves ChauvinOct 10, 1930- Jan 27, 2015For olefin metathesis
Kurt WüthrichOct 4, 1938-For biological macromolecules
John B. FennJun 15, 1917- Dec 10, 2010For biological macromolecule
Alan Jay HeegerJan 22, 1936-
For work on
conductive
polymers
Hideki ShirakawaAug 20, 1936-
For work on conductive
polymers
1963
1974
1991
2000
2002
2005
51
1953
What is a Polymer?
Monomers are the basic building units.
These contain
functional groups or double bonds
When two monomers are made to react,
usually in the presence of a catalyst, they
form a dimer.
More monomers join
successively, thus increasing the
length of the molecular chain
The resulting structure is a
POLYMER!
POLYMERS are long-chain molecules made from same repeat units 52
The same polymer can be made to various lengths (molecular weights) !!!
Tools to design properties in polymers:
• Morphology
• Rheology
• Molecular weight
Lightweighting, strength, etc.
e.g. learn from UHMWPE, DUHMWPE
Non-chemical routes
Packaging Innovations- Power of Polymers (1)
53No other material has this kind of veratility
Technical:
• Improved barrier properties
• Printability
Environmental:
• Oxodegradable
• Biodegradabale
• Bio-compostable
• Bacterium that eats PET : Ideonella sakaiensis 201-F6, Kyoto Univ, 11 May 2016
• Enzyme based treatments of plastic waste
Modifications to polymer chemistry
54
Packaging Innovations- Power of Polymers (2)
Increasing global consumption and disposal: A need to accept the right alternatives
55
Food Packaging Innovations (1) - Product Design
In-mould Labelling
• Here, the label gets applied on the packaging surface simultaneously with the plastic manufacturing
• BENEFITS:
• It reduces container weight
• Thereby, reducing eco-burden
Intelligent Packaging-Interactive
• Use of
• oxygen absorbers
• odour absorbers
• CO2 absorbers
• BENEFITS:
• Enhanced retention of nutrition of packaged food
• Enhanced retention of freshness of packaged food
Intelligent Packaging-Display
• Real-time indication of:
• nutritional value
• odour
• Discoloration
• Accordingly, price adjustments
• Instructions for disposal of packaged food items
• BENEFITS:
• Consumer can make informed decisions
56
Food Packaging Innovations (2) - Chemistry based
Bio-based plastics
• Bio-based plastics undergo decomposition in a specified period under composting conditions in industrial facilities
• Made from biomass/avocado seeds, they degrade naturally
• Some commercial examples:
• PLA (Poly Lactic Acid)
• PHA (Poly Hydroxyalkanoates)
• Bio PTT (PolyTrimethylene Terephthalate)
• 40% energy savings in production vis-à-vis their petrochemical counterparts
The Edible Water Bottle: Ooho!
• Launched in Berlin in Sep 2015
• This is the first project of Skipping Rocks Lab, a London-based startupco-founded by Rodrigo Garcia Gonzalez, Guillaume Couche and Pierre Paslier.
• Encapsulates water within a double gelatinous membrane using the culinary technique of spherification
• A new alternative packaging-simple, cheap, resistant, hygienic, biodegradable and even edible
Click here to see a video -https://www.youtube.com/watch?v
=-J68mz2agIA#t=1316/11/2015
Convenience of plastics, while limiting the environmental impact
Section 6 :
Epilogue
PET/PLASTICS ARE A BOON TO MANKIND 57
• Better Stiffness & Impact
• Maintain or improve longevity and wear
• Reduce thermal and electrical conductivity
• Improves Barrier in Packaging
• Better Stiffness & Impact
• Maintain or improve longevity and wear
• Reduce thermal and electrical conductivity
• Improves Barrier in Packaging
Improve Performance
• Add more flexibility to the design process
• Simplify coloring and decorating finished parts
• Decorate “in-mold”
• Add more flexibility to the design process
• Simplify coloring and decorating finished parts
• Decorate “in-mold”
Enhance Design & Appearance
• Eliminate assembly processes, painting and secondary operations
• Improve quality, Create more highly complex parts
• Consolidate parts, save time and money
• Eliminate assembly processes, painting and secondary operations
• Improve quality, Create more highly complex parts
• Consolidate parts, save time and money
Simplify Manufacturing
• No shattering into shards
• No leaching beyond permissible limits
• No absorbing of essential oils
• No corrosion
• No shattering into shards
• No leaching beyond permissible limits
• No absorbing of essential oils
• No corrosion
Safety
• Eliminate human contact with harmful metals
• Use less energy and generate less waste
• Increase opportunities for recycling
• Inherently lightest and further lightweighting
• Eliminate human contact with harmful metals
• Use less energy and generate less waste
• Increase opportunities for recycling
• Inherently lightest and further lightweighting
Reduce Environmental
Impact
Why Plastics?
58No material is perfect. Each material/industry needs to build on its USPs.
PLASTICS are the best compromise in meeting competing requirements.
PET – boon to mankind
As we approach the 10 billion population mark• Pressure on land for food vs fuel vs fibre vs packaging material
• Water security challenges
• Increasing aspirations – for hygiene, modern materials
PET/Plastics helps civilizational progress:• Lowest ecological footprint compared to paper, textiles, glass or metals
• Safest – no leaching
• Most convenient (non-fragile, lighter, versatile, cost-effective)
• Recyclable
• Amenable to innovations
• Releases land for much needed requirements of food 59Plastics: Release land for food and meet the increasingly aspirational society
60
Acknowledgements
Ms. Swati Verma
Reliance Ind. Ltd. PET Business
Dr. Sunil Mahajan
Reliance Ind. Ltd. Polymer Business
Mr. Bidhankumar Pradhan
Reliance Ind. Ltd. PET Business
61
Can there be a better way to demonstrate the utility of PET/Plastic packaging? 62
Innovation and Product Safety: Plastics are the drivers in the new INDIAN economy 63